A Voltage-Controlled PFC Cuk Converter-Based

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832 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 48, NO. 2, MARCH/APRIL 2012 A Voltage-Controlled PFC Cuk Converter-Based PMBLDCM Drive for Air-Conditioners Sanjeev Singh, Member, IEEE, and Bhim Singh, Fellow, IEEE Abstract—This paper deals with a Cuk dc–dc converter as a single-stage power-factor-correction converter for a permanent- magnet (PM) brushless dc motor (PMBLDCM) fed through a diode bridge rectifier from a single-phase ac mains. A three-phase voltage-source inverter is used as an electronic commutator to operate the PMBLDCM driving an air-conditioner compressor. The speed of the compressor is controlled to achieve optimum air-conditioning using a concept of the voltage control at dc link proportional to the desired speed of the PMBLDCM. The stator currents of the PMBLDCM during step change in the reference speed are controlled within the specified limits by an addition of a rate limiter in the reference dc link voltage. The proposed PMBLDCM drive (PMBLDCMD) is designed and modeled, and its performance is evaluated in Matlab–Simulink environment. Simulated results are presented to demonstrate an improved power quality at ac mains of the PMBLDCMD system in a wide range of speed and input ac voltage. Test results of a developed controller are also presented to validate the design and model of the drive. Index Terms—Air-conditioner, Cuk converter, power factor (PF) correction (PFC), permanent-magnet (PM) brushless dc mo- tor (PMBLDCM), voltage control, voltage-source inverter (VSI). I. I NTRODUCTION T HE use of a permanent-magnet (PM) brushless dc motor (PMBLDCM) in low-power appliances is increasing be- cause of its features of high efficiency, wide speed range, and low maintenance [1]–[4]. It is a rugged three-phase synchro- nous motor due to the use of PMs on the rotor. The commutation in a PMBLDCM is accomplished by solid state switches of a three-phase voltage-source inverter (VSI). Its application to the compressor of an air-conditioning (Air-Con) system results in an improved efficiency of the system if operated under speed control while maintaining the temperature in the air- conditioned zone at the set reference consistently. The Air-Con exerts constant torque (i.e., rated torque) on the PMBLDCM while operated in speed control mode. The Air-Con system with PMBLDCM has low running cost, long life, and reduced mechanical and electrical stresses compared to a single-phase Manuscript received October 16, 2010; revised June 11, 2011 and October 19, 2011; accepted December 12, 2011. Date of publication January 2, 2012; date of current version March 21, 2012. Paper 2010-IACC-410.R2, presented at the 2010 Industry Applications Society Annual Meeting, Houston, TX, October 3–7, and approved for publication in the IEEE TRANSACTIONS ON I NDUSTRY APPLICATIONS by the Industrial Automation and Control Committee of the IEEE Industry Applications Society. S. Singh is with the Department of Electrical and Instrumentation Engi- neering, Sant Longowal Institute of Engineering and Technology, Longowal 148106, India (e-mail: [email protected]). B. Singh is with the Department of Electrical Engineering, Indian Institute of Technology Delhi, New Delhi 110016, India (e-mail: bhimsinghiitd@gmail. com). Digital Object Identifier 10.1109/TIA.2011.2182329 Fig. 1. Current waveform at ac mains and its harmonic spectra for the PMBLDCM drive (PMBLDCMD) without PFC. induction motor-based Air-Con system operating in “on/off” control mode. A PMBLDCM has the developed torque proportional to its phase current and its back electromotive force (EMF), which is proportional to the speed [1]–[4]. Therefore, a constant current in its stator windings with variable voltage across its terminals maintains constant torque in a PMBLDCM under variable speed operation. A speed control scheme is proposed which uses a reference voltage at dc link proportional to the desired speed of the permanent-magnet brushless direct current (PMBLDC) motor. However, the control of VSI is only used for electronic commutation based on the rotor position signals of the PMBLDC motor. The PMBLDCMD is fed from a single-phase ac supply through a diode bridge rectifier (DBR) followed by a capacitor at dc link. It draws a pulsed current as shown in Fig. 1, with a peak higher than the amplitude of the fundamental input current at ac mains due to an uncontrolled charging of the dc link capacitor. This results in poor power quality (PQ) at ac mains in terms of poor power factor (PF) of the order of 0.728, high total harmonic distortion (THD) of ac mains current at the value of 81.54%, and high crest factor (CF) of the order of 2.28. Therefore, a PF correction (PFC) converter among various available converter topologies [5], [6] is almost inevitable for a PMBLDCMD. Moreover, the PQ standards for low power equipments, such as IEC 61000-3-2 [7], emphasize on low harmonic contents and near unity PF current to be drawn from ac mains by these drives. There are very few publications regarding PFC in PMBLDCMDs despite many PFC topologies for switched- mode power supply and battery charging applications. This paper deals with an application of a PFC converter for the speed control of a PMBLDCMD. For the proposed voltage- controlled drive, a Cuk dc–dc converter is used as a PFC converter because of its continuous input and output currents, small output filter, and wide output voltage range as compared to other single switch converters [8]–[10]. Moreover, apart from PQ improvement at ac mains, it controls the voltage at dc link for the desired speed of the Air-Con. The detailed 0093-9994/$31.00 © 2012 IEEE

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A Voltage-Controlled

Transcript of A Voltage-Controlled PFC Cuk Converter-Based

Page 1: A Voltage-Controlled PFC Cuk Converter-Based

832 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 48, NO. 2, MARCH/APRIL 2012

A Voltage-Controlled PFC Cuk Converter-BasedPMBLDCM Drive for Air-Conditioners

Sanjeev Singh, Member, IEEE, and Bhim Singh, Fellow, IEEE

Abstract—This paper deals with a Cuk dc–dc converter as asingle-stage power-factor-correction converter for a permanent-magnet (PM) brushless dc motor (PMBLDCM) fed through adiode bridge rectifier from a single-phase ac mains. A three-phasevoltage-source inverter is used as an electronic commutator tooperate the PMBLDCM driving an air-conditioner compressor.The speed of the compressor is controlled to achieve optimumair-conditioning using a concept of the voltage control at dc linkproportional to the desired speed of the PMBLDCM. The statorcurrents of the PMBLDCM during step change in the referencespeed are controlled within the specified limits by an additionof a rate limiter in the reference dc link voltage. The proposedPMBLDCM drive (PMBLDCMD) is designed and modeled, andits performance is evaluated in Matlab–Simulink environment.Simulated results are presented to demonstrate an improvedpower quality at ac mains of the PMBLDCMD system in a widerange of speed and input ac voltage. Test results of a developedcontroller are also presented to validate the design and model ofthe drive.

Index Terms—Air-conditioner, Cuk converter, power factor(PF) correction (PFC), permanent-magnet (PM) brushless dc mo-tor (PMBLDCM), voltage control, voltage-source inverter (VSI).

I. INTRODUCTION

THE use of a permanent-magnet (PM) brushless dc motor(PMBLDCM) in low-power appliances is increasing be-

cause of its features of high efficiency, wide speed range, andlow maintenance [1]–[4]. It is a rugged three-phase synchro-nous motor due to the use of PMs on the rotor. The commutationin a PMBLDCM is accomplished by solid state switches ofa three-phase voltage-source inverter (VSI). Its application tothe compressor of an air-conditioning (Air-Con) system resultsin an improved efficiency of the system if operated underspeed control while maintaining the temperature in the air-conditioned zone at the set reference consistently. The Air-Conexerts constant torque (i.e., rated torque) on the PMBLDCMwhile operated in speed control mode. The Air-Con systemwith PMBLDCM has low running cost, long life, and reducedmechanical and electrical stresses compared to a single-phase

Manuscript received October 16, 2010; revised June 11, 2011 andOctober 19, 2011; accepted December 12, 2011. Date of publication January 2,2012; date of current version March 21, 2012. Paper 2010-IACC-410.R2,presented at the 2010 Industry Applications Society Annual Meeting, Houston,TX, October 3–7, and approved for publication in the IEEE TRANSACTIONS

ON INDUSTRY APPLICATIONS by the Industrial Automation and ControlCommittee of the IEEE Industry Applications Society.

S. Singh is with the Department of Electrical and Instrumentation Engi-neering, Sant Longowal Institute of Engineering and Technology, Longowal148106, India (e-mail: [email protected]).

B. Singh is with the Department of Electrical Engineering, Indian Instituteof Technology Delhi, New Delhi 110016, India (e-mail: [email protected]).

Digital Object Identifier 10.1109/TIA.2011.2182329

Fig. 1. Current waveform at ac mains and its harmonic spectra for thePMBLDCM drive (PMBLDCMD) without PFC.

induction motor-based Air-Con system operating in “on/off”control mode.

A PMBLDCM has the developed torque proportional to itsphase current and its back electromotive force (EMF), whichis proportional to the speed [1]–[4]. Therefore, a constantcurrent in its stator windings with variable voltage across itsterminals maintains constant torque in a PMBLDCM undervariable speed operation. A speed control scheme is proposedwhich uses a reference voltage at dc link proportional to thedesired speed of the permanent-magnet brushless direct current(PMBLDC) motor. However, the control of VSI is only usedfor electronic commutation based on the rotor position signalsof the PMBLDC motor.

The PMBLDCMD is fed from a single-phase ac supplythrough a diode bridge rectifier (DBR) followed by a capacitorat dc link. It draws a pulsed current as shown in Fig. 1, witha peak higher than the amplitude of the fundamental inputcurrent at ac mains due to an uncontrolled charging of the dclink capacitor. This results in poor power quality (PQ) at acmains in terms of poor power factor (PF) of the order of 0.728,high total harmonic distortion (THD) of ac mains current at thevalue of 81.54%, and high crest factor (CF) of the order of 2.28.Therefore, a PF correction (PFC) converter among variousavailable converter topologies [5], [6] is almost inevitable fora PMBLDCMD. Moreover, the PQ standards for low powerequipments, such as IEC 61000-3-2 [7], emphasize on lowharmonic contents and near unity PF current to be drawn fromac mains by these drives.

There are very few publications regarding PFC inPMBLDCMDs despite many PFC topologies for switched-mode power supply and battery charging applications. Thispaper deals with an application of a PFC converter for thespeed control of a PMBLDCMD. For the proposed voltage-controlled drive, a Cuk dc–dc converter is used as a PFCconverter because of its continuous input and output currents,small output filter, and wide output voltage range as comparedto other single switch converters [8]–[10]. Moreover, apartfrom PQ improvement at ac mains, it controls the voltage atdc link for the desired speed of the Air-Con. The detailed

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SINGH AND SINGH: VOLTAGE-CONTROLLED PFC CUK CONVERTER-BASED PMBLDCM DRIVE 833

Fig. 2. Control scheme of the proposed Cuk PFC converter-fed VSI-basedPMBLDCMD.

modeling, design, and performance evaluation of the proposeddrive are presented for an air-conditioner driven by a 0.816-kW1500-r/min PMBLDC motor.

II. PROPOSED SPEED CONTROL SCHEME OF PMBLDCMOTOR FOR AIR-CONDITIONER

Fig. 2 shows the proposed speed control scheme which isbased on the control of the dc link voltage reference as anequivalent to the reference speed. However, the rotor positionsignals acquired by Hall-effect sensors are used by an electroniccommutator to generate switching sequence for the VSI feedingthe PMBLDC motor, and therefore, rotor position is requiredonly at the commutation points [1]–[4].

The Cuk dc–dc converter controls the dc link voltage usingcapacitive energy transfer which results in nonpulsating inputand output currents [8]. The proposed PFC converter is operatedat a high switching frequency for fast and effective control withadditional advantage of a small size filter. For high-frequencyoperation, a metal–oxide–semiconductor field-effect transistor(MOSFET) is used in the proposed PFC converter, whereasinsulated gate bipolar transistors (IGBTs) are used in the VSIbridge feeding the PMBLDCM because of its operation at lowerfrequency compared to the PFC converter.

The PFC control scheme uses a current multiplier approachwith a current control loop inside the speed control loop forcontinuous-conduction-mode operation of the converter. Thecontrol loop begins with the processing of voltage error (Ve),obtained after the comparison of sensed dc link voltage (Vdc)and a voltage (V ∗

dc) equivalent to the reference speed, througha proportional–integral (PI) controller to give the modulatingcontrol signal (Ic). This signal (Ic) is multiplied with a unittemplate of input ac voltage to get the reference dc current (I∗d)and compared with the dc current (Id) sensed after the DBR.The resultant current error (Ie) is amplified and compared witha sawtooth carrier wave of fixed frequency (fs) to generate thepulsewidth modulation (PWM) pulse for the Cuk converter. Itsduty ratio (D) at a switching frequency (fs) controls the dclink voltage at the desired value. For the control of currentto PMBLDCM through VSI during the step change of thereference voltage due to the change in the reference speed, a

rate limiter is introduced, which limits the stator current of thePMBLDCM within the specified value which is considered asdouble the rated current in this work.

III. DESIGN OF PFC CUKCONVERTER-BASED PMBLDCMD

The proposed PFC Cuk converter is designed for a PMBLD-CMD with main considerations on the speed control of the Air-Con and PQ improvement at ac mains. The dc link voltage ofthe PFC converter is given as

Vdc = VinD/(1 − D) (1)

where Vin is the average output of the DBR for a given ac inputvoltage (Vs) related as

Vin = 2√

2Vs/π. (2)

The Cuk converter uses a boost inductor (Li) and a capacitor(C1) for energy transfer. Their values are given as

Li =DVin/ {fs(ΔILi)} (3)C1 =DIdc/{fsΔVC1} (4)

where ΔILi is a specified inductor current ripple, ΔVC1 is aspecified voltage ripple in the intermediate capacitor (C1), andIdc is the current drawn by the PMBLDCM from the dc link.

A ripple filter is designed for ripple-free voltage at the dclink of the Cuk converter. The inductance (Lo) of the ripplefilter restricts the inductor peak-to-peak ripple current (ΔILo)within a specified value for the given switching frequency (fs),whereas the capacitance (Cd) is calculated for the allowedripple in the dc link voltage (ΔVCd) [7], [8]. The values of theripple filter inductor and capacitor are given as

Lo = (1 − D)Vdc/ {fs(ΔILo)} (5)Cd = Idc/(2ωΔVCd). (6)

The PFC converter is designed for a base dc link voltageof Vdc = 298 V at Vs = 220 V for fs = 40 kHz, Is = 4.5 A,ΔILi = 0.45 A (10% of Idc), Idc = 3.5 A, ΔILo = 3.5 A (≈Idc), ΔVCd = 4 V (1% of Vo), and ΔVC1 = 220 V (≈ Vs).The design values are obtained as Li = 6.61 mH, C1 = 0.3 μF,Lo = 0.82 mH, and Cd = 1590 μF.

IV. MODELING OF PFCCONVERTER-BASED PMBLDCMD

The PFC converter and PMBLDCMD are the main compo-nents of the proposed drive, which are modeled by mathemati-cal equations, and a combination of these models represents thecomplete model of the drive.

A. PFC Converter

The modeling of the PFC converter consists of the modelingof a speed controller, a reference current generator, and a PWMcontroller as given hereinafter.

1) Speed Controller: The speed controller is a PI controllerwhich tracks the reference speed as an equivalent referencevoltage. If, at the kth instant of time, V ∗

dc(k) is the reference

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TABLE IELECTRONIC COMMUTATOR OUTPUT BASED ON THE

HALL-EFFECT SENSOR SIGNALS [6], [11]

dc link voltage and Vdc(k) is the voltage sensed at the dc link,then the voltage error Ve(k) is given as

Ve(k) = V ∗dc(k) − Vdc(k). (7)

The PI controller output Ic(k) at the kth instant after process-ing the voltage error Ve(k) is given as

Ic(k)=Ic(k − 1) + Kp {Ve(k) − Ve(k − 1)} + KiVe(k) (8)

where Kp and Ki are the proportional and integral gains of thePI controller.

2) Reference Current Generator: The reference current atthe input of the Cuk converter (i∗d) is

i∗d = Ic(k)uVs (9)

where uVs is the unit template of the ac mains voltage, calcu-lated as

uVs = vd/Vsm; vd = |vs|; vs = Vsm sin ωt (10)

where Vsm and ω are the amplitude (in volts) and frequency (inradians per second) of the ac mains voltage.

3) PWM Controller: The reference input current of the Cukconverter (i∗d) is compared with its current (id) sensed afterDBR to generate the current error Δid = (i∗d − id). This currenterror is amplified by gain kd and compared with fixed frequency(fs) sawtooth carrier waveform md(t) [6] to get the switchingsignal for the MOSFET of the PFC Cuk converter as

if kdΔid > md(t) then S = 1 else S = 0 (11)

where S denotes the switching of the MOSFET of the Cukconverter as shown in Fig. 2 and its values “1” and “0” represent“on” and “off” conditions, respectively.

B. PMBLDCMD

The PMBLDCMD consists of an electronic commutator,a VSI, and a PMBLDCM.

1) Electronic Commutator: The electronic commutator usessignals from Hall-effect position sensors to generate the switch-ing sequence for the VSI as shown in Table I [6], [11].

Fig. 3. Equivalent circuit of a VSI-fed PMBLDCMD.

2) VSI: The output of VSI to be fed to phase “a” of thePMBLDC motor is calculated from the equivalent circuit of aVSI-fed PMBLDCM shown in Fig. 3 as

vao = (Vdc/2) for Sa1 = 1 (12)vao = (−Vdc/2) for Sa2 = 1 (13)vao = 0 for Sa1 = 0, and Sa2 = 0 (14)van = vao − vno (15)

where vao, vbo, vco, and vno are the voltages the three phases(a, b, and c) and neutral point (n) with respect to the virtualmidpoint of the dc link voltage shown as “o” in Fig. 3. Thevoltages van, vbn, and vcn are the voltages of the three phaseswith respect to the neutral terminal of the motor (n), and Vdc isthe dc link voltage. The values 1 and 0 for Sa1 or Sa2 representthe “on” and “off” conditions of respective IGBTs of the VSI.

The voltages for the other two phases of the VSI feeding thePMBLDC motor, i.e., vbo, vco, vbn, and vcn, and the switchingpattern of the other IGBTs of the VSI (i.e., Sb1, Sb2, Sc1, andSc2) are generated in a similar way.

3) PMBLDC Motor: The PMBLDCM is modeled in theform of a set of differential equations [11] given as

van = Ria + pλa + ean (16)

vbn = Rib + pλb + ebn (17)

vcn = Ric + pλc + ecn. (18)

In these equations, p represents the differential operator(d/dt), ia, ib, and ic are currents, λa, λb, and λc are fluxlinkages, and ean, ebn, and ecn are phase-to-neutral back EMFsof PMBLDCM, in respective phases; R is the resistance ofmotor windings/phase.

Moreover, the flux linkages can be represented as

λa =Lsia − M(ib + ic) (19)

λb =Lsib − M(ia + ic) (20)

λc =Lsic − M(ib + ia) (21)

where Ls is the self-inductance/phase and M is the mutualinductance of PMBLDCM winding/phase.

The developed torque Te in the PMBLDCM is given as

Te = (eania + ebnib + ecnic)/ωr (22)

where ωr is the motor speed in radians per second.

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Since PMBLDCM has no neutral connection

ia + ib + ic = 0. (23)

From (15)–(21) and (23), the voltage (vno) between theneutral point (n) and midpoint of the dc link (o) is given as

vno = {vao + vbo + vco − (ean + ebn + ecn)} /3. (24)

From (19)–(21) and (23), the flux linkages are given as

λa = (Ls + M)ia, λb = (Ls + M)ib, λc = (Ls + M)ic.(25)

From (16)–(18) and (25), the current derivatives in general-ized state-space form are given as

pix = (vxn − ixR − exn)/(Ls + M) (26)

where x represents phase a, b, or c.The back EMF is a function of rotor position (θ) as

exn = Kbfx(θ)ωr (27)

where x can be phase a, b, or c and accordingly fx(θ) representsa function of rotor position with a maximum value ±1, identicalto trapezoidal induced EMF, given as

fa(θ) = 1 for 0 < θ < 2π/3 (28)fa(θ) = 1 {(6/π)(π − θ)} − 1 for 2π/3 < θ < π (29)fa(θ) = −1 for π < θ < 5π/3 (32)fa(θ) = {(6/π)(π − θ)} + 1 for 5π/3 < θ < 2π. (31)

The functions fb(θ) and fc(θ) are similar to fa(θ) with phasedifferences of 120◦ and 240◦, respectively.

Therefore, the electromagnetic torque expressed as

Te = Kb {fa(θ)ia + fb + fc(θ)ic} . (32)

The mechanical equation of motion in speed derivative formis given as

pωr = (P/2)(Te − Tl − Bωr)/(J) (33)

where ωr is the derivative of rotor position θ, P is the number ofpoles, Tl is the load torque in newton meters, J is the momentof inertia in kilogram square meters, and B is the frictioncoefficient in newton meter seconds per radian.

The derivative of rotor position is given as

pθ = ωr. (34)

Equations (16)–(34) represent the dynamic model of thePMBLDC motor.

V. PERFORMANCE EVALUATION OF PMBLDCMD

The proposed PMBLDCMD is modeled in Matlab–Simulink environment, and its performance is evaluated for anAir-Con compressor load. The compressor load is considered asa constant torque load equal to the rated torque (5.2 N · m) withvariable speed as required by an Air-Con system. A 0.816-kWrating PMBLDCM is used to drive the air-conditioner, thespeed of which is controlled effectively by controlling the dclink voltage. The detailed data of the motor are given in the

Fig. 4. Performance of the proposed PFC drive under speed control at220-V ac input. (a) Starting performance of the proposed drive at 1000 r/min.(b) Proposed drive under speed control from 1000 to 1500 r/min. (c) Proposeddrive under speed control from 1000 to 500 r/min.

Appendix. The performance of the proposed PFC drive isevaluated on the basis of various parameters such as THD andCF of the ac mains current and displacement power factor(DPF) and PF at different speeds of the motor as well asvariable input ac voltage. For the performance evaluation ofthe proposed drive under input ac voltage variation, the dclink voltage is kept constant at 298 V which is equivalent to a1500-r/min speed of the PMBLDCM. Figs. 4–8 and Tables IIand III show the obtained results of the proposed PMBLDCMDin a wide range of the speed and the input ac voltage.

A. Performance of PMBLDCMD During Starting

The performance of the PMBLDCMD during starting isevaluated while feeding it from 220-V ac mains with thereference speed set at 1000 r/min and rated torque. Fig. 4(a)shows the starting performance of the drive depicting voltage(vs) and current (is) at ac mains, voltage at dc link (Vdc),speed of motor (N), electromagnetic torque (Te), and statorcurrent of phase “a” (ia). A rate limiter is introduced in thereference voltage to limit the starting current of the motor aswell as the charging current of the dc link capacitor. The PI

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Fig. 5. Variation of dc link voltage with speed for proposed PFC drive at ratedtorque and 220-V ac input.

Fig. 6. PQ indices of proposed drive under speed control at rated torque and220 V ac input. (a) Variation of Is and its THD. (b) Variation of DPF and PF.

Fig. 7. Current waveform at input ac mains and its harmonic spectra for theproposed drive under steady-state condition at rated torque and 220 V ac input.(a) Is and THD at 500 r/min. (b) Is and THD at 1500 r/min.

Fig. 8. PQ indices with input ac voltage variation at a constant dc link voltageof 298 V (≈1500 r/min). (a) Variation of Is and its THD. (b)Variation of DPFand PF.

controller tracks the reference speed so that the motor attainsreference speed smoothly within 0.375 s while keeping thestator current within the desired limits, i.e., double the ratedvalue. The current waveform at input ac mains is in phasewith the supply voltage demonstrating near unity PF during thestarting.

TABLE IIPERFORMANCE OF THE PROPOSED DRIVE UNDER SPEED CONTROL AT

220-V INPUT AC VOLTAGE (Vs)

TABLE IIIPQ INDICES WITH INPUT AC VOLTAGE (Vs) VARIATION AT 1500 r/min

B. Performance of PMBLDCMD Under Speed Control

Figs. 4–6 show the performance of PMBLDCMD for speedcontrol at constant rated torque (5.2 N · m) and 220-V acmains voltage during transient and steady-state conditions ofthe PMBLDCM.

1) Transient Condition: The performance of the drive dur-ing the speed transients is evaluated for acceleration and re-tardation of the compressor and shown in Fig. 4(b) and (c).The reference speed is changed from 1000 to 1500 r/min andfrom 1000 to 500 r/min for the performance evaluation of thecompressor at rated load under speed control. It is observed thatthe speed control is fast and smooth in either directions, i.e.,acceleration or retardation, with PF maintained at near unityvalue. Moreover, the stator current of PMBLDCM is less than

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twice the rated current due to the rate limiter introduced in thereference voltage.

2) Steady-State Condition: The performance ofPMBLDCMD under steady-state speed condition is obtained atdifferent speeds as summarized in Table II which demonstratesthe effectiveness of the proposed drive in a wide speed range.Fig. 5 shows the linear relation between motor speed anddc link voltage. Since the reference speed is decided by thereference voltage at dc link, it is observed that the control ofthe reference dc link voltage controls the speed of the motor.

C. PQ Performance of the PMBLDCMD

The performance of PMBLDCMD in terms of PQ indices,i.e., THDi, CF, DPF, and PF, is obtained for different speeds aswell as loads. These results are shown in Figs. 6 and 7 and Ta-ble II. Fig. 6(a) and (b) shows near unity PF and reduced THDof ac mains current in wide speed range of the PMBLDCM.The THDi and harmonic spectra of ac mains current drawn bythe proposed drive at 500- and 1500-r/min speeds are shown inFig. 7(a) and (b) demonstrating less than 5% THDi in a widerange of speed.

D. Performance of the PMBLDCMD UnderVarying Input AC Voltage

The performance of the proposed PMBLDCMD is evaluatedunder varying input ac voltage at rated load (i.e., rated torqueand rated speed) to demonstrate the effectiveness of the pro-posed drive for Air-Con system in various practical situationsas summarized in Table III.

Fig. 8(a) and (b) shows the current and its THD at ac mains,DPF, and PF with ac input voltage. The THD of ac mainscurrent is within specified limits of international norms [7] atnear unity PF in a wide range of ac input voltage.

VI. HARDWARE IMPLEMENTATION

The designed proposed PFC controller is validated on a de-veloped prototype of the drive in the laboratory. The developedhardware prototype for the speed control of PMBLDCMD usesa VSI along with a single-phase DBR and a dc capacitor. Thedata of a PMBLDC motor used for hardware implementationare given in the Appendix. The shaft of the PMBLDCM iscoupled with a separately excited dc generator for applicationof mechanical load in terms of an equivalent electrical load.

For the implementation of the PWM current control algo-rithm, a digital signal processor (DSP) developed by Microchipnamed as dsPIC 30F6010 is used in this system, which alsogenerates switching signals for VSI acting as an electronic com-mutator for the PMBLDCM. The switching signals for the VSIare obtained using the PWM channels of the dsPIC 30F6010,whereas the PWM signal for the PFC switch is generated atone of the I/O pins. The feedback signals of current and voltageare obtained using voltage and current sensor circuits designedin the voltage range of analog-to-digital converters of theprocessor. The unit template is generated using a zero-crossingdetector circuit from the input ac mains voltage signal. Theswitching frequency of the PWM signal is kept constant at

Fig. 9. (a) Test results of nonisolated Cuk PFC converter-fed PMBLDCMDduring starting at reference speed of 1000 r/min. (b) Test results of non-isolated Cuk PFC converter-fed PMBLDCMD during speed control from500 to 1500 r/min. (c) Test results of nonisolated Cuk PFC converter-fedPMBLDCMD demonstrating speed control through voltage control from1000 to 500 r/min. (d) Test results of nonisolated Cuk PFC converter-fedPMBLDCMD during steady-state condition at reference speed of 1500 r/min.(e) Test results in terms of harmonic spectrum and waveform of ac mainscurrent of nonisolated Cuk PFC converter-fed PMBLDCMD during steady-state condition at reference speed of 1500 r/min.

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40 kHz, whereas it is the fundamental frequency correspondingto the speed of the motor for the electronic commutatorfeeding VSI.

Test results are recorded using a power analyzer of Flukemake and a four-channel digital storage oscilloscope of Agi-lent make. Test results are shown in Fig. 9(a)–(e) for variousperformance parameters such as starting, speed control, and PQimprovement. Smooth speed control is obtained during accel-eration and deceleration by controlling the voltage at dc link asdemonstrated in Fig. 9(b) and (c). Fig. 9(d) demonstrates thetest results during steady-state condition at a 1500-r/min speedwhile the THD of current at input ac mains is recorded within5% as shown in Fig. 9(e). These test results show conformitywith the simulation results and validate the proposed voltagecontrol scheme for speed control of PMBLDCMD along withPQ improvement at input ac mains while using a single DSP.

VII. CONCLUSION

A new speed control strategy for a PMBLDCMD using thereference speed as an equivalent voltage at dc link has beensimulated for an air-conditioner employing a Cuk PFC con-verter and experimentally validated on a developed controller.The speed of PMBLDCM has been found to be proportional tothe dc link voltage; thereby, a smooth speed control is observedwhile controlling the dc link voltage. The introduction of arate limiter in the reference dc link voltage effectively limitsthe motor current within the desired value during the transientconditions. The PFC Cuk converter has ensured near unity PFin a wide range of the speed and the input ac voltage. Moreover,PQ indices of the proposed PFC drive are in conformity tothe International Standard IEC 61000-3-2 [7]. The proposedPMBLDCMD has been found as a promising variable speeddrive for the Air-Con system. Moreover, it may also be usedin the fans with PMBLDC motor drives on the trains recentlyintroduced in Indian Railways. These PMBLDC motor drive-based fans have similar PQ problems as they use a simplesingle-phase diode rectifier and no speed control. These fansalso have inrush current problems. All these PQ problems ofpoor PF, inrush current, and speed control in these fans on thetrains in Indian Railways may be mitigated by the proposedvoltage-controlled PFC Cuk converter-based PMBLDCMD.

APPENDIX

Rated power: 0.816 kW; rated speed: 1500 r/min; ratedtorque: 5.2 N · m; poles: 6; stator resistance (R): 3.57 Ω/ph;inductance (L + M): 9.165 mH/ph; back EMF constant (Kb):1.3 V · s/rad; inertia (J): 0.068 kg · m2; source impedance(Zs): 0.03 p.u.; switching frequency of PFC switch (fs):40 kHz; PI speed controller gains (Kp): 0.145; (Ki): 1.85.

REFERENCES

[1] T. Kenjo and S. Nagamori, Permanent Magnet Brushless DC Motors.Oxford, U.K.: Clarendon, 1985.

[2] T. J. Sokira and W. Jaffe, Brushless DC Motors: Electronic Commutationand Control. New York: Tab, 1989.

[3] J. R. Hendershort and T. J. E. Miller, Design of Brushless Permanent-Magnet Motors. Oxford, U.K.: Clarendon, 1994.

[4] J. F. Gieras and M. Wing, Permanent Magnet Motor Technology—Designand Application. New York: Marcel Dekker, 2002.

[5] B. Singh, B. N. Singh, A. Chandra, K. Al-Haddad, A. Pandey, andD. P. Kothari, “A review of single-phase improved power quality ac–dcconverters,” IEEE Trans. Ind. Electron., vol. 50, no. 5, pp. 962–981,Oct. 2003.

[6] N. Mohan, M. Undeland, and W. P. Robbins, Power Electronics: Convert-ers, Applications and Design. Hoboken, NJ: Wiley, 1995.

[7] Limits for Harmonic Current Emissions (Equipment Input Current ≤ 16 APer Phase), Int. Std. IEC 61000-3-2, 2000.

[8] S. Cuk and R. D. Middlebrook, “Advances in switched-mode power con-version Part-I,” IEEE Trans. Ind. Electron., vol. IE-30, no. 1, pp. 10–19,Feb. 1983.

[9] C. J. Tseng and C. L. Chen, “A novel ZVT PWM Cuk power factorcorrector,” IEEE Trans. Ind. Electron., vol. 46, no. 4, pp. 780–787,Aug. 1999.

[10] B. Singh and G. D. Chaturvedi, “Analysis, design and development ofsingle switch Cuk ac–dc converter for low power battery charging appli-cation,” in Proc. IEEE PEDES, 2006, pp. 1–6.

[11] C. L. Puttaswamy, B. Singh, and B. P. Singh, “Investigations on dynamicbehavior of permanent magnet brushless dc motor drive,” Elect. PowerCompon. Syst., vol. 23, no. 6, pp. 689–701, Nov. 1995.

Sanjeev Singh (S’09–M’11) was born in Deoria,India, in 1972. He received the B.E. (electrical) de-gree from Avadhesh Pratap Singh University, Rewa,India, in 1993, the M.Tech. degree from Devi AhilyaVishwa Vidyalaya, Indore, India, in 1997, and thePh.D. degree from the Indian Institute of TechnologyDelhi, New Delhi, India, in 2011.

He joined the North India Technical ConsultancyOrganisation, Chandigarh, India, as a Project Officer,in 1997, and in 2000, he joined Sant LongowalInstitute of Engineering and Technology, Longowal,

India, as a Lecturer in the Department of Electrical and Instrumentation Engi-neering. He is currently an Assistant Professor in the Department of Electricaland Instrumentation Engineering, Sant Longowal Institute of Engineering andTechnology. His areas of interest include power electronics, electrical machinesand drives, energy efficiency, and power quality.

Dr. Singh is a Life Member of the Indian Society for Technical Education,the Systems Society of India, and The Institution of Engineers (India).

Bhim Singh (SM’99–F’10) was born in Rahamapur,India, in 1956. He received the B.E. (electrical) de-gree from the University of Roorkee, Roorkee, India,in 1977, and the M.Tech. and Ph.D. degrees fromthe Indian Institute of Technology (IIT) Delhi, NewDelhi, India, in 1979 and 1983, respectively.

In 1983, he joined the Department of ElectricalEngineering, University of Roorkee, as a Lecturer,and in 1988, he became a Reader. In December 1990,he joined the Department of Electrical Engineering,IIT Delhi, as an Assistant Professor, where he be-

came an Associate Professor in 1994 and a Professor in 1997. Since September2007, he has been the Asea Brown Boveri Chair Professor at IIT Delhi. Hisfields of interest include power electronics, electrical machines, electric drives,renewable energy generation, power quality, flexible ac transmission systems,and high-voltage direct-current transmission systems. He has guided 35 Ph.D.dissertations, 120 M.E./M.Tech./M.S.(R) theses, and 60 B.E./B.Tech. projects.

Dr. Singh was the recipient of the Khosla Research Prize of the Universityof Roorkee in 1991. He is a recipient of the J.C. Bose and Bimal K. BoseAwards of The Institution of Electronics and Telecommunication Engineers(IETE) for his contributions in the field of power electronics. He is also arecipient of the Maharashtra State National Award of the Indian Society forTechnical Education (ISTE) in recognition of his outstanding research work inthe area of power quality. He was the recipient of the IEEE Power and EnergySociety Delhi Chapter Outstanding Engineer Award for the year 2006. He wasthe General Chair of the IEEE International Conference on Power Electronics,Drives and Energy Systems (PEDES’2006) held in New Delhi. He is a Fellowof the Indian National Academy of Engineering, The National Academy ofScience, India, The Institution of Engineers (India), and IETE, and a LifeMember of the ISTE, Systems Society of India, and National Institution forQuality and Reliability.